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Parts & Service Manual Part No. 80170

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1. 6 8 10 Genie Superlift Advantage Part No 80170 December 2005 Section 8 Mast and Winch Components REV C FIGURE 8 D Item Part No Description Qty ltem Part No Description Qty 1 10597 Screw HHG 4 49999 Pulley with Bearing 1 2 13 x 1 25 inches GR 5 4 65 x 4 05 inches SLA 5 ne ni 1 SUAS ia ane 2 10597 Screw HHC 49999 Pulley with Bearing 1 2 13 x 1 25 inches GR 5 4 65 x 4 05 inches SIERT 3 SLA 10 EE 4 10597 Screw HHG 49999 Pulley with Bearing 1 2 13 x 1 25 inches GR 5 4 65 x 4 05 inches SLAB uns 5 SLA 15 vunne 6 10597 Screw HHG 49999 Pulley with Bearing 1 2 13 x 1 25 inches GR 5 4 65 x 4 05 inches EE EE 7 SLA 20 EE 8 10597 Screw HHG 49999 Pulley with Bearing 1 2 13 x 1 25 inches GR 5 4 65 x 4 05 inches SLA 25 ossessi 9 BE E WE 10 2 37038 Shim Washer 5 80680 Pulley Guard 0 51 x 0 8 x 0 125 inch SLAD Sans ei 2 SL S unne 2 80680 Pulley Guard 37038 Shim Washer SLATO sn 4 0 51 x 0 8 x 0 125 inch 80680 Pulley Guard GE 4 SMA AWR 6 37038 Shim Washer 80680 Pulley Guard 0 51 x 0 8 x 0 125 inch SLAZZ0 ende 8 SLA 15 aan en 6 80680 Pulley Guard 37038 Shim Washer SLA
2. 8 18 Genie Superlift Advantage Part No 80170 October 2004 Section 9 Accessories Section Nine Accessories Part No 80170 Genie Superlift Advantage 9 1 Section 9 Accessories October 2004 Figure 9 A Forks REV B 9 2 Genie Superlift Advantage Part No 80170 October 2004 Section 9 Accessories REV B litem Part No 32564 S 107161 1 32548 S 2 48301 3 32908 107162 4 33674 5 80679 6 33366 S 7 32375 8 32541 S 9 8220 10 6198 11 32539 Description Qty Item Adjustable Fork Assembly with 12 Decals before serial number SLA04 25259 USA Canadian and Australian models after serial number SLA04 25258 includes Items1 4 Adjustable Fork Assembly with Decals Asia S America and European models after serial number SLA04 25258 includes Items 1 4 32907 107163 13 32906 Adjustable Fork 2 Toggle Pin 0 5 x 8 13 inches 3 Adjustable Carrier Assembly with Decals before serial number SLA04 25259 USA Canadian and Australian models after serial number SLA04 25258 1 Adjustable Carrier Assembly with Decals Asia S America and European models after serial number SLA04 25258 107164 Snap Pin 0 375 x 0 25 inch 2 Ball Retaining Pin 0 5 x 2 7 inches 111111111 2 Fork Extension
3. 80157 Manuals Genie Industries offers the following support documents for these models Title Part No Genie Superlift Advantage Operator s Manual before January 2004 221 21112 33499 Genie Superlift Advantage Operator s Manual after December 2004 97550 Genie Superlift Advantage Parts and Service Manual before July 2001 2 2 ee 32283 Genie Superlift Advantage Parts and Service Manual after June 2001 iisipan 80170 EMI Safety Manual 27581 Part No 80170 Genie Superlift Advantage xi October 2004 How To Order Parts Please be prepared with the following information when ordering replacement parts for your Genie product Machine model number Machine serial number Genie part number Part description and quantity Purchase order number Ship to address Desired method of shipment Name and telephone number of the authorized Genie Distributor in your area RH KRRRRA Use the Service Parts Fax Order Form on the next page and fax your order to our Parts Department If you don t know the name of your authorized distributor or if your area is not currently serviced by an authorized distributor please call Genie Industries Machine Information Model Serial Number Date of Purchase Authorized Genie Distributor Phone Number Genie North America Telephone 425 556 6551 Toll Free 877 367 5606 in U S A and Canada Fax 425 556 8659 Genie
4. 1 9 6190 Cable Keeper Kit 1 80159 Carriage Bolt 10 24 x 0 63 inch 80160 Cable Keeper 80161 Internal Star Washer 5 8 inch 25625 Hex Nut 10 24 10 6184 Drum Spacer 1 11 31946 Drum Lock Bolt 1 12 6770 Winch Gear Cover 111111 1 13 7256 Screw HHC 5 16 18 x 6 inches GR 2 14 6782 Lock Nut 5 16 18 15 6185 Drum Bolt 1 Part No 80170 Genie Superlift Advantage 8 15 Section 8 Mast and Winch Components December 2005 Figure 8 F Winch Components Two speed REV C 8 16 Genie Superlift Advantage Part No 80170 December 2005 Section 8 Mast and Winch Components EEE ZE DZE DEER REV C FIGURE 8 F Item Part No Description Qty ltem Part No Description Qty 32946 Winch Assembly with Decals 14 40116 Retaining Ring 0 75 inch 1 before serial number SLA04 25259 15 40126 Sintered Iron Bearing USA Canadian and 0 75 inch Australian models after serial number SLA04 25258 16 80155 Pinion Shaft Assembly 1 107158 Winch Assembly with Decals 17 38028 Low Profile Nylock Nut before serial number 5 8 11 SLA04 25259 Asia S America and European 18 40125 Handle 8 inches 2 models after serial number SLA04 25258 19 72264 Input Shaft Assembly 1 40130 Cable Keeper Kit
5. 111111121111 2 Snap Pin 0 63 x 2 29 inches 2 Flat Fork Socket 2 Screw HHC 1 2 13 x 4 inches GR 5 Nylock Nut 1 2 13 Flat Fork Casting 2 Part No FIGURE 9 A Description Qty Flat Forks Carrier Assembly with Decals before serial number SLA04 25259 USA Canadian and Australian models after serial number SLA04 25258 cuscini 1 Flat Forks Carrier Assembly Asia S America and European models after serial number SLA04 25258 Standard fork with Decals before serial number SLA04 25259 USA Canadian and Australian models after serial number SLA04 25258 1 Standard fork with Decals Asia S America and European models after serial number SLA04 25258 Part No 80170 Genie Superlift Advantage Section 9 Accessories October 2004 Figure 9 B Pipe Cradle Load Platform and Boom Arm REV B 9 4 Genie Superlift Advantage Part No 80170 October 2004 Section 9 Accessories ZZ ZLA ZY A REV B FIGURE 9 B item Part No Description Qty 1 8170 Wing Nut 1 4 20 2 33045 U bolt 1 4 20 x 1 5 x 3 75 x 1 25 MERES 4 42 52 4 3 80597 Pipe Cradle 2211121112 2 4 32937 Load Platform Assembly with Decals before serial number SLA04 25259 USA Canadian and Australian models after serial number SLA04 25258 1 107165 Load Platform Assembly with Dec
6. Decals with Words before serial number SLA04 25259 Part No 80170 Genie Superlift Advantage October 2004 Section 6 Decals j K o LLL 0000000 ZI REV B FIGURE 6 A Item Part No Description Qty 1 32715 Notice Flat Fork Setup 1 2 32718 Warning Flat Fork Safety 1 3 33468 Warning No Riders 5 4 32775 Warning Fall Hazard 1 5 32716 Notice Boom Setup 2 6 32714 Notice Adjustable Fork Setup 1 7 32687 Warning Standard Fork Safety 1 8 32717 Warning Boom Safety 1 9 32686 Warning Machine Safety 1 10 32938 Label Use this Winch 1 11 32939 Warning Crushing Hazard Brake Lock ne 1 12 31072 Label Operator s Manual Storage Container 1 13 32689 Cosmetic SLA 5 1 11 2 32690 Cosmetic SLA 10 32691 Cosmetic SLA 15 32692 Cosmetic SLA 20 32693 Cosmetic SLA 25 14 52675 Caution Damaged Machine 1 15 32885 Warning Silent Winch 1 16 52983 Cosmetic Superlift Advantage 2 17 33982 Plate Serial Number before serial number SLA03 20337 rrrnnnnnrrrnrnnrrnnvnrrnrnnn 1 80939 Plate Serial Number after serial number SLA03 20336 18 32770 Label Two speed Winch 1 Part No 80170 Genie Superlift Advantage 6 3 Section 6 Decals
7. Checklist B Procedures REV B B 1 Inspect All Welds Weld inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage may result in an unsafe operating condition 1 Visually inspect the welds in the following locations Winch mounting plate Loading wheels steer handle Base Legs and stabilizers Load handling attachment s B 2 Clean the Columns Clean columns are essential to good machine performance and safe operation Extremely dirty conditions may require that the columns be cleaned more often 1 Raise all columns to full height 2 Visually inspect the inner and outer channels of the columns for debris or foreign material If necessary use a mild cleaning solvent to clean the columns AWARNING 20dily injury hazard This procedure will require the use of additional access equipment Do not place ladders or scaffold on or against any part of the machine Performing this procedure without the proper skills and tools could result in death or serious injury Dealer service is strongly recommended Part No 80170 Genie Superlift Advantage 3 7 Section 3 Scheduled Maintenance Procedures October 2004 CHECKLIST B PROCEDURES B 3 Check the Winch Operation Detection of damage to the winch is essential to safe machine operation An unsafe working condition exists if the winch is damaged or not operating correctly A daily check
8. Detection of damage or a faulty safety brake system is essential for safe machine operation An unsafe working condition exists if the system is damaged or faulty and does not allow the mast to sequence properly free of hesitation and binding AWARNING Bodily injury hazard This procedure requires specific repair skills and a suitable workshop Attempting this procedure without these skills could result in death or serious injury or significant component damage Dealer service is strongly recommended ACAUTION Bcdily injury hazard Beware of sharp edges Wear protective gloves when performing this procedure 1 Fasten a load handling attachment to the carriage use the forks or the boom if possible Do not place any weight on the load handling attachment 2 Raise the carriage until it is half way up the front column 3 Grasp the bottom carriage and lift it approximately 12 inches 30 cm then release the carriage Part No 80170 Genie Superlift Advantage Section 3 Scheduled Maintenance Procedures October 2004 EEE M O M CHECKLIST C PROCEDURES REV B Result The carriage should stop within 7 Raise the front column approximately 5 to 8 inches 12 7 to 20 3 cm and the safety 12 inches 30 cm to disengage the safety brake should engage brake ACAUTION Crushing hazard Do not stand 8 Operate the winch until the front column is fully directly under the carriage or load raised and the second column is half way u
9. REV A Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation Report to use for each inspection Store completed forms as required Maintenance Schedule There are three types of maintenance inspections that must be performed according to a schedule daily quarterly and annual The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into three subsections A B and C Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Annual or every 1000 hours A B C Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years 3 2 Genie Superlift Advantage Part No 80170 Pre Delivery Preparation It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory
10. properly route the cable could result in a winch brake failure CAUTION Component damage hazard Do not allow the cable to become twisted during installation or mast sequencing problems may occur Be sure the cable guard is located over the retaining pin on the pulley mounting block Be sure the pulley spins freely after reassembling the pulley assembly 13 Apply Loctite removeable thread sealant to the fastener and install the pulley assembly onto the column 14 Assemble the columns in reverse order of disassembly Part No 80170 Genie Superlift Advantage 5 9 Section 5 Repair Procedures October 2004 Winches REV A 3 1 7 Slide the pinion shaft to the right and remove A the pinion spacer pinion plate ratchet gear and One speed Winch friction disks Turn the pinion gear BEER 00 counterclockwise and slide it off the left side of How to Disassemble a the shaft One speed Winch 8 Remove the pinion shaft from the winch housing ACAUTION Bodily injury hazard Cables can m fray Always wear adequate hand 9 Remove both pinion bushings Use a soft metal protection when handling cable drift equal to the outside diameter of the bushing and tap with a rubber mallet Component damage hazard CAUTION Place a block in between the walls of the winch housing to prevent the housing from bending while 3 Remove both handle retaining fasteners removing the bushings Remove the handles from the pinion shaft 1 Fully low
11. 1 11 1 1 22 48301 Screw HHC 23 Ref 3 8 16 x 1 25 inches GR 5 Nylock Nut 3 8 16 Straddle Base Assembly SLA 5 re 1 Straddle Base Assembly SLA 10 Straddle Base Assembly SLA 15 Rear Swivel Caster BEX ZINES ren 2 Square Nut 3 8 16 Straddle Retaining Block 4 Straddle Base Wedge 2 Wear Pad 4 16 x 1 25 x 0 5 inch 2 Screw HHC 3 8 16 x 1 5 inches GR 5 Flat Washer 3 8 inch Screw BHHS 3 8 16 x 1 inch Arm Straddle Left Side 1 Hold down Assembly with Decals SLA 5 SLA 10 and SLA 15 before serial number SLA04 25259 USA Canadian and Australian models after serial number SLA04 25258 includes items 12 and 14 Section 7 Base Components FIGURE 7 B Description Qty Hold down Assembly with Decals SLA 5 SLA 10 and SLA 15 Asia S America and European models after serial number SLA04 25258 includes items 12 and 14 Cotter Pin 0 125 x 0 75 inch 1 Glide Button 1 Toggle Pin 0 5 x 8 13 inches 1 Carriage refer to Figure 8 D Part No 80170 Genie Superlift Advantage Section 7 Base Components April 2005 Figure 7 C Base Components All Models REV C OG OOD O 7 8 Genie Superlift Advantage Part No 80170 April 2005 Secti
12. Mast and Winch Components p REV C FIGURE 8 C item Part No Description Qty 16 33811 Coupler Bar SLA 20 and SLA 25 1 17 57019 Down Stop Block SLA 10 rernrrrvrrrvvrrnvrrsvvrrnvernnn 1 57019 Down Stop Block SLANS es Gate 4 57019 Down Stop Block SLA 20 rrrnrrnnnrrrnvvrrnversvvrrnvernnn 6 57019 Down Stop Block SLA 25 aaa aa aaaaszaaacnane 8 18 57022 Down Stop Rubber Bumper SLA 10 saa szoa SMA 1 57022 Down Stop Rubber Bumper STASI 4 57022 Down Stop Rubber Bumper SLA 20 sea 6 57022 Down Stop Rubber Bumper SLA 2S See de 8 19 57023 Shoulder Bolt 3 8 16 x 0 75 inch GR 5 SLA 10 SLA 15 SLA 20 and SLA 25 models 20 57021 Down Stop Tube SLATO eramanen ones 1 57021 Down Stop Tube SLA 15 a saa asza aa cnans 4 57021 Down Stop Tube SLA 20 satte Se 6 57021 Down Stop Tube SLA 25 isitin 8 21 57018 Down Stop Plunger Block SLA 10 SLA 15 SLA 20 and SLA 25 e 112111 1112 1 22 57024P Down Stop Plate SLA 10 SLA 15 SLA 20 and SLA 25 e 11 211121112 1 23 13066 Hardened Flat Washer 1 2 inch Part No 80170 Genie Superlift Advantage 8 9 Section 8 Mast and Winch Components December 2005 Figure 8 D Columns Pulleys and Cables REV C
13. drum and out through the remaining hole on the left side wall of the drum a number one column b cable c winch drum d cable keeper clip 22 Insert the end of the cable under the cable keeper clip approximately 1 2 inch 13 mm and tighten the cable keeper clip fasteners 23 While holding the cable tight on the drum rotate the drum and spool the cable onto the drum evenly CAUTION Component damage hazard Be sure the cable winds onto the winch drum evenly Genie Superlift Advantage Part No 80170 October 2004 Section 5 Repair Procedures REV A 3 2 Two speed Winch How to Disassemble a Two speed Winch ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable 1 Fully lower the carriage and remove the load handling attachment 2 Remove the cable retaining fasteners from the winch drum Remove the cable from the drum 3 Remove both handle retaining fasteners from the pinion shaft Remove the handles 4 Remove the drum bolt and spacer Remove the drum drum gear cover and housing spacer 5 Remove the input shaft cover 6 Remove the mounting fasteners from the spring and ball housing 7 Remove the two springs and balls from the spring and ball housing WINCHES 8 Slide the input shaft out of the winch housing 9 Remove the retaining ring from the pinion shaft 10 Remove the lock nut from the end of the pinion shaft located on the out
14. 8 16 x 1 25 inches GR 5 Right Side Mast Siiffener 1 Roller 1 75 x 0 72 inch 4 Mast Stiffener Spacer 4 56 x 0 75 inch u 1 Nylock Nut 1 2 13 Screw HHC 1 2 13 x 6 inches GR 8 1 Left Side Mast Stiffener 1 Flat Washer 1 2 inch before serial number SLC05 30640 Nylon Washer 51x 75 x 125 inch after serial number SLC05 30639 Roller Bolt 1 2 13 x 1 84 inches 2 Roller Guard 2 Winch Mount with Decals before serial number SLA04 25259 USA Canadian and Australian models after serial number SLA04 25258 1 Winch Mount with Decal before serial number SLA04 25259 Asia S America and European models after serial number SLA04 25258 Qty Item 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 Section 8 Mast and Winch Components SSS SS SSS Part No 12343 6091 6600 31822 6653 7265 6732 11978 100309 6587 33385 6564 57788 37202 33540 107156 35834 Ref 49991 FIGURE 8 A Description Qty Screw HHC 1 4 20 x 3 inches GR 5 Nylock Nut 1 4 20 Instruction Tube with Caps 1 Tube Cap Rubber Cushioned Clamp 1 88 inches 2 Steel Rivet 0 25 x 0 375 inch 2 Screw HHC 1 2 13 x 3 25 inches GR 5 Nylon Flat Washer 1 2 inch Pin Assembly with Lanyard 1 R bber Gripens 2 Push on Washer 0 75 inch 2 Shim
15. 8 D Item Part No Description Qty ltem Part No Description Qty 7 8255 Screw HHC 16 57033 S Number 2 Column 3 8 16 x 0 75 inch GR 5 SLA 10 after serial number GW WA 14 5599 3360 cccecsessesseeseesseeseeseens 1 8255 Screw HHC 57033 S Number 2 Column 3 8 16 x 0 75 inch GR 5 SLA 15 after serial number SLA 25 NTE 20 5599 3361 1 11 11111111111 2 57033 S Number 2 Column 8 6019 Screw HHC SLA 20 after serial number 9 8 16 x 1 25 inches GR 5 5599 3404 nr 3 all models 57033 S Number 2 Column SLA 25 after serial number 3 R oo ee EE 4 m sa Arakne Bracket 1 17 57034 Carriage SLA 5 after serial ee number 5599 3745 1 11 32483 Roll Pin 0 25 x 0 5 inch 57034 Carriage SLA 10 after serial all models aaa wna 1 number 5599 3360 57034 Carriage SLA 15 after serial 12 8177 Screw HHC number 5599 3361 1 2 13 x 1 5 inches GR 5 57035 Carriage SLA 20 after serial all models number 5599 3404 57035 Carriage SLA 25 after serial 13 6198 Nylock Nut 1 2 13 number 5599 3827 all models 14 6443 Cable Assembly SLA 5 rennrnrrrnrvrrrnrverrrnnnerrrrnenrn 1 6444 Cable Assembly SLA 10 32903 Cable Assembly SLA 15 32904 Cable Assembly SLA 20 32905 Cable Assembly SLA 25 15 57032 S Number 1 Column SLA 5 after serial number 5599 3745 1 57032 S Number 1 Column SLA 10 after serial number 5599 3360
16. 97545 Warning Lock Brake 1 10 97546 Label Two speed Shift 1 k 33982 Plate Serial Number before serial number SLA03 20337 srrrnnrrnnvnrnnvrnnvnrrnre 1 80939 Plate Serial Number after serial number SLA03 20336 Part No 80170 Genie Superlift Advantage 6 7 Section 6 Decals October 2004 Notes 6 8 Genie Superlift Advantage Part No 80170 October 2004 Section 7 Base Components Section Seven Base Components Part No 80170 Genie Superlift Advantage 7 1 Section 7 Base Components October 2004 Figure 7 A Base Components Standard REV B 7 2 Genie Superlift Advantage Part No 80170 October 2004 REV B litem Part No 1 2 Ref 80171 5 107171 107181 80172 5 107172 107182 80173 S 107173 107183 80174 S Description Qty Columns refer to Figure 8 D Standard Base Assembly with Decals SLA 5 before serial number SL04 25259 Standard Base Assembly with Decals SLA 5 after serial number SL04 25258 USA Canadian and Australian models after serial number SLA04 25258 Standard Base Assembly with Decals SLA 5 after serial number SL04 25258 Asia S America and European models after serial number SLA04 25258 S
17. October 2004 Figure 6 B Decals with Words after serial number SLA04 25258 REV B 52983 97529 32686 32885 32938 32939 32770 52675 31072 32770 52983 32689 or 32690 or 32691 or 32692 or 32693 32689 or 32690 or 32691 or 32692 or 32693 6 4 Genie Superlift Advantage Part No 80170 October 2004 Section 6 Decals REV B FIGURE 6 B Item Part No Description Qty 1 31072 Label Operator s Manual Container irasus 1 2 32686 Warning Machine Safety 1 3 32687 Warning Standard Fork Safety 1 4 32689 Cosmetic SLA 5 1 2 32690 Cosmetic SLA 10 32691 Cosmetic SLA 15 32692 Cosmetic SLA 20 32693 Cosmetic SLA 25 5 32714 Notice Adjustable Fork Setup 1 6 32715 Notice Flat Fork Setup 1 7 32716 Notice Boom Setup 1 8 32717 Warning Boom Safety 1 9 32718 Warning Flat Fork Safety 1 10 32770 Label Two speed Winch 1 11 32775 Warning Fall Hazard 1 12 32885 Warning Silent Winch 1 13 32938 Label Use this Winch 1 14 32939 Warning Crushing Hazard Brake Lock 1 15 33468 Warning No Riders 5 16 526
18. Standard Base Assembly with Decals SLA 25 after serial number SL04 25258 USA Canadian and Australian models after serial number SLA04 25258 Standard Base Assembly with Decals SLA 25 after serial number SL04 25258 Asia S America and European models after serial number SLA04 25258 Shim Washer 0 45 x 0 75 x 0 063 inch 3 Hold down Spring 1 1 Screw HHC 3 8 16 x 1 inch GR5 Nylock Nut 3 8 16 Rear Swivel Caster 5 x 2 inches 2 Screw HHG 3 8 16 x 1 25 inches GR 5 Wear Pad 4 16 x 1 25 x 0 5 inch 2 Screw HHC 3 8 16 x 1 5 inches GR 5 Flat Washer 3 8 inch Cotter Pin 0 125 x 0 75 inch 1 This list continues on the next page Part No 80170 Genie Superlift Advantage Section 7 Base Components October 2004 FIGURE 7 A REV B 7 4 Genie Superlift Advantage Part No 80170 October 2004 REV B litem Part No 13 14 15 16 58750 107153 58095 107154 11890 38696 Ref Description Qty Hold down Assembly with Decals SLA 5 SLA 10 and SLA 15 before serial number SLA04 25259 USA Canadian and Australian models after serial number SLA04 25258 includes items 12 and 14 Hold down Assembly with Decals SLA 5 SLA 10 and SLA 15 Asia S America and E
19. UK Parts Telephone 44 0 1476 584352 Parts Fax 44 0 1476 584340 Genie Australia Parts Telephone 617 03375 1660 Parts Fax 617 03375 1002 Genie France Parts Telephone 33 0 237 26 09 99 Parts Fax 33 0 237 31 50 10 Genie Germany Parts Telephone 49 0 4202 885223 Parts Fax 49 0 4202 885225 Genie Scandinavia Parts Telephone 46 31 3409612 Parts Fax 46 31 3409613 Genie Iberica Parts Telephone 34 93 5795042 Genie Brazil Parts Telephone 55 114 1665755 Parts Fax 55 114 1665754 Genie Japan Parts Telephone 81 33 4536082 Parts Fax 81 33 4536083 Genie China Parts Telephone 86 215 3852570 Parts Fax 86 215 3852569 xii Genie Superlift Advantage Part No 80170 remove this page and make copies remove this page and make copies Service Parts Fax Order Form IG Fax to 425 556 8659 or Toll Free 888 274 6192 A TEREX COMPANY International 1 425 556 8659 Please fill out completely Date Account Number Your Name Your Fax Number Your Phone Number Bill To Ship To Purchase Order Number Ship Via Model s Serial No s Optional Equipment Part Number Description Quantity Price All back ordered parts will be shipped when available via the same ship method as the original order unless Noted below O Ship complete order only No back orders O Ship all available parts and contact customer on disposition
20. by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures October 2004 MM UO uuu This page intentionally left blank 3 4 Genie Superlift Advantage Part No 80170 October 2004 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Y NIR Checklist C Y NIR A 1 Pre operation C 1 Lubricate the casters Serial number Inspection and wheels Date A 2 Function Tests C 2 Mast assembly wear C 3 Replace winch Machine owner Checklist B YINIR friction disks B 1 Welds C 4 Safety brake system Inspected by print if equipped B 2 Clean columns C 5 Painted surfaces Inspector signature B 3 Winch Operation B 4 Inspect and lubricate Inspector title winch B 5 Carriage hold down Inspector company bar Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Annual or 1000 hour Inspection A B C Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair p
21. delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond WA 98073 9730 425 881 1800 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries Rev A Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected
22. of back ordered parts O Other please specify For GENIE INDUSTRIES USE ONLY Order Number Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code October 2004 AOL This page intentionally left blank xiii Genie Superlift Advantage Part No 80170 October 2004 Section 2 Specifications Specifications REV A Model SLA 5 SLA 10 SLA 15 SLA 20 SLA 25 Height Stowed 781 2 in 781 2 in 781 2 in 781 2 in 781 2 in 2m 2m 2m 2m 2m Width 311 2 in 311 2 in 311 2 in 311 2 in 311 2 in Standard Base 80 cm 80 cm 80 cm 80 cm 80 cm Width stabilizers lowered 785 8 in 785 8 in 785 8 in 785 8 in 785 8 in Standard Base 2m 2m 2m 2m 2m Width Minimum 311 2 in 311 2 in 311 2 in NA NA Straddle Base 80 cm 80 cm 80 cm Width Maximum 58 in 58 in 58 in NA NA Straddle Base 1 5m 1 5m 1 5m Length Stowed 29 in 29 in 29 in 29 in 31 in 74 cm 74 cm 74 cm 74 cm 79 cm Length Operating 591 2 in 591 2 in 721 2 in 801 2 in 801 2 in 1 5m 1 5m 184 cm 204 cm 204 cm Ground 2 in 2 in 2 in 2 in 2 in Clearance 50 8 mm 50 8 mm 50 8 mm 50 8 mm 50 8 mm Load Capacity 1000 Ibs 1000 Ibs 800 lbs 800 lbs 650 lbs at 18 inch 46 cm load center 454 kg 454 kg 363 kg 363 kg 295 kg Net Weight Standard Base 215 Ibs 260 lbs 317 Ibs 405 Ibs 450 lbs 97 5 kg 117 9 kg 143 8 kg 183 7 kg 204 1 kg Net Weight Straddle Base 258 Ibs 303 Ibs 360 Ibs NA NA 117 0 kg 137 4 kg 163 3 kg Load Handling Attachments Len
23. of the winch operation allows the inspector to identify changes in the operating condition of the winch that might indicate damage 1 Visually inspect all the winch components for damage 2 Raise the carriage through a partial cycle and release the winch handles Result The winch should operate smoothly free of hesitation or binding The load should not lower when the handles are released 3 Fully lower the carriage Result The winch should operate smoothly free of hesitation or binding REV B B 4 Inspect and Lubricate the Winch Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Carefully lubricate the following areas with automotive grease Cable drum gear Teeth on the pinion gear that mesh with the cable drum gear Threads on the pinion shaft under the pinion gear Models with Two speed winch The teeth on the slow and the fast speed gears where they mesh together Do not apply grease to brake friction disks or rachet gear 2 Carefully lubricate both pivot points on each ratchet pawl with 30W oil 3 8 Genie Superlift Advantage Part No 80170 October 2004 Section 3 Scheduled Maintenance Procedures Er REV B CHECKLIST B PROCEDURES 3 Measure each friction disk for wear Replace the friction disk if it measures les
24. outside of the frame spacer with multi purpose grease Insert the frame spacer into the drum 13 Install the cable drum Be sure the drum gears mesh with the ratchet gears 14 Install the drum bolt keeper Push the drum bolt through the winch housing drum cover and drum Be sure the head of the drum bolt is on the drum gear side of the winch 15 Place the drum gear cover in position with the drum bolt slot under the drum bolt keeper 16 Install the drum bolt jam nut hand tight 17 Install the housing spacer with the head of the housing spacer bolt on the right side of the winch and through the slotted portion of the drum gear cover Place the nut on the end of the bolt and tighten 18 Torque the drum bolt nut to 20 to 25 ft lbs 27 to 34 Nm Component damage hazard CAUTION Overtightening the drum bolt jam nut may cause damage to the frame spacer and prevent the drum from spinning freely 19 Lubricate the teeth of the drum gear and the pinion nut that meshes with the drum gear with multi purpose grease CAUTION Component damage hazard Do not allow grease or oil onto the friction disks or the ratchet gear REV A 20 Rotate the drum so that the two square cable keeper holes are at the top Install the cable keeper clip to the outside of the drum with the two carriage bolts coming through from the inside Install the lock washers and nuts finger tight Do not tighten 21 Route the end of the cable around the winch
25. to avoid possible injury or death ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 80170 Genie Superlift Advantage 3 1 Section 3 Scheduled Maintenance Procedures October 2004 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform this procedure D oi a
26. 004 Section 5 Repair Procedures REV A 12 Secure the top of the mast to the support 13 Attach a lifting strap from an overhead crane to the base and lift the machine to a horizontal position Slide a second suitable structure capable of supporting it under the mast next to the base AWARNING Crushing hazard The machine could become unbalanced and fall if not properly supported by the overhead crane 14 Remove the mounting fasteners from both mast braces at the base 15 Remove the base mounting fasteners Remove the base from the machine When installing the base be sure that the mast and the base are square Mast Assembly 2 1 Mast Assembly How to Disassemble the Mast Assembly Removal of the base is only necessary when the number one column is to be removed See 1 1 How to Remove the Base 1 Fully lower the carriage and remove the load handling attachment 2 Remove the cable retaining fasteners from the winch drum Remove all of the cable from the drum 3 Liftthe machine slightly with an overhead crane While tilting backwards with the carriage facing up guide the machine over onto a suitable structure Bodily injury hazard Use proper CAUTION lifting techniques when lifting the mast assembly Crushing hazard The machine ACAUTION may become unbalanced and fall if not properly supported 4 Remove the mounting fastener from the cable anchor at the top of the last column carriage
27. 1 Pinion Gear One speed Winch 7590 Pinion Gear Two speed Winch 80157 Pinion Shaft One speed Winch 32891 Ratchet Pawl Kit One speed Winch 40458 Ratchet Pawl Kit Two speed Winch 40117 Cable Keeper Kit One speed Winch 6190 Primary Shaft Assembly 72264 Cable Assembly SLA 5 models 35143 Cable Assembly SLA 10 models 35144 Cable Assembly SLA 15 models 35145 Cable Assembly SLA 20 models 35146 Pin Assembly with Lanyard 2221121111112 32940 Roller Bolt 1 2 13 x 1 84 inches 32475 Nylatron Roller 1 75 x 0 72 inch 32473 Safety Brake Assembly 35101 Safety Brake Tool Assembly 33875 Loctite Thread LOCK 65764 Genie Superlift Cabling Procedure Video 52701 Part No Parts Stocking List Required Parts The following parts are required to perform maintenance procedures as outlined in the Genie Superlift Advantage Parts and Service Manual Description Part No White Lithium Grease 91670 Cable Replacement Coupler 1 1 111 1 12402 Disc Brake One speed Winch 1 11121111 7571 Disc Brake Two speed Winch
28. 20 6145 Screw HHC includes items 5 8 and 9 1 4 20 x 1 5 inches GR 5 1 78037 808 Ne R 21 40115 Brake Spring Spacer 2 2 4828 Nylock Nut 3 8 16 22 6889 Low Profile Nylock Nut 1 4 20 3 80145 Reel Lock Bolt 1 23 40127 Detent Block Assembly 1 4 80146 Screw HHC 40509 Detent Spring 2 1 4 20 x 5 25 inches 40510 Detent Ball ssiri 2 80156 Detent Block 1 5 6091 Nylock Nut 1 4 20 24 80157 Pinion Gear 1 6 80147 Screw FHC Threaded 1 2 inch 25 37061 Disc BrakKe 2 7 80148 Reel Cover 1 1 26 37062 Ratchet Gear 1 8 80149 Carriage bolt 27 40122 PINION Plate 1 fn EIN 28 40123 Brake Spacer 1 11 1 9 37065 Cable Keeper 1 29 37064 Pinion Shatt BUSHING aceiasi 1 al 19 Soag Fer MEME AMEN 30 40128 Base Spacer 111111111111111 1 11 40113 Reel Spacer 1 12 80151 Gear Cover 111111112111111 1 13 40117 Ratchet Pawl Kit 1 8516 Screw HHC 3 8 16 x 1 5 inches GR 5 5397 Flat Washer 5 16 inch 80154 Ratchet Pawl 80153 Ratchet Spring 80152 Ratchet Spacer 4828 Nylock Nut 3 8 16 Part No 80170 Genie Superlift Advantage 8 17 Section 8 Mast and Winch Components October 2004 Notes
29. 57032 S Number 1 Column SLA 15 after serial number 5599 3361 57032 S Number 1 Column SLA 20 after serial number 5599 3404 57032 S Number 1 Column SLA 25 after serial number 5599 3827 Part No 80170 Genie Superlift Advantage 8 13 Section 8 Mast and Winch Components December 2005 Figure 8 E Winch Components One speed 8 14 Genie Superlift Advantage Part No 80170 December 2005 Section 8 Mast and Winch Components M REV C FIGURE 8 E ltem Part No Description Qty ltem Part No Description Qty 32945 Winch Assembly with Decals 16 6034 Hex Jam Nut 1 2 13 before serial number SLA04 25259 USA 17 7584 Frame Spacer 1 Canadian and Australian r models alter saralnumber 18 32890 Pinion Shaft Spacer 1 SLA04 25258 19 7591 Pinion Plate 1 11111 1 107157 Winch Assembly with Decals before serial number 20 6777 Ratchet Gear 1 SLA04 25259 Asia S America and European models after serial number SLA04 25258 1 7571 DISC Brake a 2 2 7590 PIRION G6aT aaa wada 1 3 32891 Pinion Shalit eco ia casa 1 4 6200 Retaining Ring 0 75 inch 1 5 6199 Pinion Shaft Bushing 2 6 33143 Winch Handle 6 inches SEAS aoi Aer 2 33144 Winch Handle 8 inches SLA 10 SLA 15 SLA 20 and SLA 25 7 6086 Low Profile Nylock Nut 1 2 13 8 40458 Ratchet Pawl Kit
30. 75 Caution Damaged Machine 1 17 52983 Cosmetic Superlift Advantage 2 18 82959 Danger Electrocution Hazard 2 19 97529 Caution Bodily Injury Hazard 1 20 33982 Plate Serial Number before serial number SLA03 20337 srrrnnvrrvrrsnvrrnvnrrnrn 1 80939 Plate Serial Number after serial number SLA03 20336 Part No 80170 Genie Superlift Advantage 6 5 Section 6 Decals October 2004 Figure 6 C Decals with Symbols REV B 52983 97532 82487 82964 97542 97541 97545 97546 32770 52983 or 32692 32689 or 32690 or 32691 or 32692 or 32693 97539 6 6 Genie Superlift Advantage Part No 80170 October 2004 Section 6 Decals REV B FIGURE 6 C Item Part No Description Qty 1 32689 Cosmetic SLA 5 1 1111 2 32690 Cosmetic SLA 10 32691 Cosmetic SLA 15 32692 Cosmetic SLA 20 32693 Cosmetic SLA 25 LEZ Z 2 52983 Cosmetic Superlift Advantage 2 3 82487 Label Read the Manual 2 4 82964 Warning No Riders 1 5 97532 Caution Bodily Injury Hazard 1 6 97539 Danger Electrocution Hazard 2 7 97541 Label Use this Winch 1 8 97542 Warning Load Center Chart 1 9
31. PSJ nee 10 0 51 x 0 8 x 0 125 inch EE 8 6 32470 Pulley Mount 37038 Shim Washer SLA 5 Aa 1 0 51 x 0 8 x 0 125 inch 32470 Pulley Mount SLA 25 EE 10 SEAN vs ee 3 32470 Pulley Mount 3 6052 Shim Washer GEO una 5 0 5 x 0 875 x 0 063 inch 32470 Pulley Mount SLA 5 ossessi 2 SEA DO nues 7 6052 Shim Washer 32470 Pulley Mount 0 5 x 0 875 x 0 063 inch EE 9 EEE 4 2 6052 Shim Washer 7 8255 Screw HHC 0 5 x 0 875 x 0 063 inch 9 8 16 x 0 75 inch GR 5 EEE EEG 6 SLA 5 er GA 2 6052 Shim Washer 8255 Screw HHC 0 5 x 0 875 x 0 063 inch 9 8 16 x 0 75 inch GR 5 SLA ns nu ne 8 SLA 10 Re 6 6052 Shim Washer 8255 Screw HHC 0 5 x 0 875 x 0 063 inch 9 8 16 x 0 75 inch GR 5 SLA ar NA 10 GE ETE 10 This list continues on the next page Part No 80170 Genie Superlift Advantage 8 11 Section 8 Mast and Winch Components December 2005 FIGURE 8 D REV C 6 8 12 Genie Superlift Advantage Part No 80170 December 2005 Section 8 Mast and Winch Components EEE ZZOZ REV C FIGURE
32. SLA 25 models Flat Washer 1 2 inch 0 562 x 1 375 x 0 109 inch SLA 5 SLA 10 SLA 15 SLA 20 and SLA 25 models before serial number SLC05 30640 Nylon Washer 51x 75 x 125 inch SLA 5 SLA 10 SLA 15 SLA 20 and SLA 25 models after serial number SLC05 30639 Number 1 Column refer to Figure 8 D Roller Guard GW CY Roller Cuard BLAGIO un anna Roller Guard SLA 15 Roller Guard SLA 20 isise ir eieiei Roller Guard SLA 25 esiin Roller 1 75 x 0 72 inch SAS creer Roller 1 75 x 0 72 inch OWEN Roller 1 75 x 0 72 inch SLA 15 2 Roller 1 75 x 0 72 inch SLA 2O rs nennen Roller 1 75 x 0 72 inch SLA 25 cnnneenneenneneeennenn Roller Bolt 1 2 13 x 1 84 inches SLA 5 1 1 Roller Bolt 1 2 13 x 1 84 inches SLA 10 Roller Bolt 1 2 13 x 1 84 inches SLA 15 Roller Bolt 1 2 13 x 1 84 inches SLA 20 Roller Bolt 1 2 13 x 1 84 inches SLA 25 Qty Item 14 15 Section 8 Mast and Winch Components Z O O OK Part No Ref 35463 35408 35443 35443 35443 35443 35443 35101 35101 35101 32522 6019 12013 4828 6052 FIGURE 8 0 Description Qty Number 2 Column refer to Figure 8 D Screw FHS 3 8 16 x 1 5 inches SLA 5 SLA 10 SLA 15 SLA 20 and SLA 25 models Square Nut 3 8 16 Pla
33. V B 6 Lower the base end of the machine 9 Visually inspect the bottom of each column for clearance between the roller wheel and the 7 Rotate the mast assembly until the carriage is adjacent column surface on top Result There should be a gap of less than 0 062 inch 1 57 mm between the roller wheel and the column If the mast inspection results in a measurement that is not within specification refer to Repair procedure 2 1 How to Disassemble the Mast Assembly 8 Visually inspect the top of each column for clearance between the roller wheel and the adjacent column surface Result There should be a gap of less than 0 062 inch 1 57 mm between the roller wheel and the column If the mast inspection results in a measurement that is not within specification See Repair procedure 2 1 How to Disassemble the Mast Assembly 3 12 Genie Superlift Advantage Part No 80170 October 2004 Section 3 Scheduled Maintenance Procedures REV B CHECKLIST C PROCEDURES C 3 C 4 Replace the Winch Friction Disks Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Replace the winch friction disks See Repair procedure 3 1 How to Disassemble a One speed Winch or 3 2 How to Disassemble a Two speed Winch Inspect the Safety Brake System if equipped
34. Washer 0 75 x 1 125 x 0 093 inch 4 Wheel 6 x 2 inches 2 Inner Axle Bushing Loading Wheel Assembly with Decals before serial number SLA04 25259 USA Canadian and Australian models after serial number SLA04 25258 includes items 24 27 1 Loading Wheel Assembly with Decals before serial number SLA04 25259 Asia S America and European models after serial number SLA04 25258 includes items 24 27 Winch Spacer One speed SLA 5 and SLA 10 1 Winch Assembly refer to Figures 8 E or 8 F Winch Spacer Two speed SLA 5 and SLA 10 1 Part No 80170 Genie Superlift Advantage Section 8 Mast and Winch Components October 2004 Figure 8 B Mast Components View 2 REV B c Tal A Mea SH l l Poa q R PR a O a 2 ai i W O 0 6 8 4 Genie Superlift Advantage Part No 80170 October 2004 Section 8 Mast and Winch Components p ee m TE ET REVB FIGURE 8 B item Part No Description Qty 1 10597 Screw HHC 1 2 13 x 1 25 inches GR 5 2 6095 Flat Washer 1 2 inch before serial number SLC05 30640 109560 Nylon Washer 51x 75 x 125 inch after serial number SLC05 30639 3 6198 Nylock Nut 1 2 13 4 35081 Cable Anchor bef
35. ace damaged kinks frays and cable See Repair damage procedure 2 2 How to Replace the Lifting Cable Check pulley and guard for damage and replace if needed Check all cable pulleys to verify that the cable is properly routed Replace damaged component Check pulley and pulley guard for damage Re install cable if removed during inspection Inspect winch drum and Replace damaged pinion gear for damage components OR consult the Genie Industries Service Department h Consult the Genie Industries Service Department Part No 80170 Genie Superlift Advantage 4 3 Section 4 Troubleshooting Flow Charts October 2004 Chart 3 REV A Winch Will Not Operate Is the load centered Re position load to properly and free of eliminate obstruction Be obstructions sure load is properly centered Check the cable for Remove the bound Replace the damaged binding at the winch binding cable and inspect the component s drum or inside the mast cable and related assembly components for damage not binding Check winch for proper Replace the damaged operation See component See Repair Maintenance procedure procedure 3 1 How to B 3 Inspect and Disassemble a One Lubricate the Winch Speed Winch or 3 2 How to Disassemble a Two Speed Winch Check carriage and Replace damaged mast for damaged column OR consult the column s Genie Industries Servic
36. als Asia S America and European models after serial number SLA04 25258 5 32579 S Clevis Boom 1 6 80679 Ball Retaining Pin 0 5 x 2 7 inches 1 7 48301 Toggle Pin 0 5 x 8 13 inches 1 8 32567 S Boom Arm Assembly with Decals before serial number SLA04 25259 USA Canadian and Australian models after serial number SLA04 25258 includes items 5 7 1 107166 Boom Arm Assembly with Decals Asia S America and European models after serial number SLA04 25258 includes items 5 7 Part No 80170 Genie Superlift Advantage 9 5 Section 9 Accessories October 2004 Figure 9 C Rear Wheels 9 6 Genie Superlift Advantage Part No 80170 REV B L r A October 2004 Section 9 Accessories REV B FIGURE 9 C Item Part No Description Qty a 35848 S Rear Wheel Accessory Complete 1 33831 S Wheel Spacer 2 35064 Rear Wheel 10 x 2 75 inches 3 33830 S Rear Spacer Mount Right Side icttandediaivtin diva 4 6094 Cotter Pin 0 125 x 1 inch 5 57237 Transport Wheels Axle Rod 6 6564 Shim Washer 0 75 x 1 125 x 0 093 inch 7 33829 S Rear Spacer Mount Left Side 8 6019 Screw HHC 3 8 16 x 1 25 inches GR 5 9 4828 Nylock Nut 3 8 16 Part No 80170 Genie Superlift Ad
37. and lower last Verify weight of load a against machine capacity not over loaded not Check position of load for proper centering fonr centered Inspect the column debris channels and pulley tracks for foreign debris no debris Check for cable binding binding on cable pulleys not binding Check the roller wheels for damage OR no grease yes no Check each mast yes column for damage no Consult the Genie Industries Service Department centered Remove excess weight from machine and re check Center load and re check Clean the columns See Maintenance procedure B 2 Clean the Columns Inspect pulley and pulley no guard for damage yes Replace the pulley or pulley guard See Repair procedure 2 3 How to Replace the a Pulley Mast Installed Replace the damaged roller wheel s OR apply grease to the roller bolt Replace the damaged column OR consult the Genie Industries Service Department REV A Inspect cable for damage yes Replace the cable See Repair procedure 2 2 How to Replace the Lifting Cable Genie Superlift Advantage Part No 80170 October 2004 Section 4 Troubleshooting Flow Charts ae Chart Carriage Will Replace broken cable Not Raise A an BIC AU 2 How to Replace the But Winch Lifting Cable Will Operate Be sure the carriage hold down bar is not engaged Inspect the cable for Repl
38. asher 1 2 inch 22 32882 Leg Stabilizer 1 21111 11 2 23 5224 Screw HHC 3 8 16 x 2 inches GR5 Part No 80170 Genie Superlift Advantage 7 9 Section 7 Base Components October 2004 Notes 7 10 Genie Superlift Advantage Part No 80170 Section 8 Mast and Winch Components Section Eight Mast and Winch Components Genie Superlift Advantage Section 8 Mast and Winch Components October 2004 Figure 8 A Mast Components View 1 REV B p NN NH Wa This diagram reflects the Two speed winch spacer holes that are aligned differently to the winch mount weldment Exploded view below reflects the one speed ee se 9 Ge O 8 2 Genie Superlift Advantage Part No 80170 October 2004 REV B Item 12 13 14 Part No 4828 6097 6097 6326 6175 6019 100424 32473 33843 6198 13005 100425 6095 109560 32475 32474 80162 107155 Description Nylock Nut 3 8 16 Flat Washer 3 8 inch One speed winch Flat Washer 3 8 inch Two speed winch Screw HHC 3 8 16 x 3 inches GR 5 SLA 5 and SLA 10 Screw HHC 3 8 16 x 1 inch GR5 SLA 15 SLA 20 and SLA 25 Screw HHC 3
39. bricated more often 1 Visually inspect each caster and wheel for cuts cracks or unusual wear 2 Move the machine on a flat smooth surface and check that the casters and wheels roll smoothly free of hesitation and binding 3 Pump grease into the caster or wheel until it can been seen coming out of the bearing gap Grease Type Lithium based Mast Assembly for Wear Detection of excessive or unusual wear in the mast assembly is essential for safe machine operation An unsafe working condition exists if the mast assembly has excessive wear and or does not operate smoothly free of hesitation and binding 1 Attach a lifting strap from an overhead crane or similar lifting device to the lifting point on the top of the mast Rotate the carriage hold down bar over the carriage and operate the winch to apply tension to the lifting cable 2 Lift the machine slightly with the overhead crane and guide it onto a suitable structure capable of supporting it AWARNING Crushing hazard The machine will fall if not properly supported by the overhead crane 3 Lowerthe top of the mast onto the suitable structure 4 Attach a lifting strap from an overhead crane to the base of the machine 5 Lift the base with the overhead crane until the mast is level and place another suitable structure under the mast Part No 80170 Genie Superlift Advantage Section 3 Scheduled Maintenance Procedures October 2004 CHECKLIST C PROCEDURES RE
40. d workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed To re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 80170 Genie Superlift Advantage 5 1 Section 5 Repair Procedures October 2004 Base Assembly 1 1 Base How to Remove the Base 1 Loosen the locking screw and retract the extendable legs if equipped Fully lo
41. e Department Consult the Genie Industries Service Department 4 4 Genie Superlift Advantage Part No 80170 October 2004 Section 5 Repair Procedures Observe and Obey M Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Repairs Start M Read understand and obey the safety rules and operating instructions in the Genie Superlift Advantage Operator s Manual M Be sure that all necessary tools and parts are available and ready for use M Be sure the capacities of sawhorses or other supports are sufficient to withstand machine weight See Specifications section for the machine weight M Be sure overhead cranes or other lifting devices are of ample capacity to handle machine weight See Specifications section for specific weight M Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions M Unless otherwise specified perform each procedure with the machine in the following configuration Machine positioned on a firm level surface Carriage fully lowered Casters locked Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equippe
42. easured from ground to bottom of shackle Vertical Barrel Stacker 30 gallon 4 ft 8 ft 10 in 13 ft 9 in NA NA 1 2m 2 7m 4 2m 55 gallon 3ft10 in 8 ft 8 in 13 ft 7 in 1 2m 2 6m 4 1m Note measured from ground to bottom of barrel Rotating Barrel Handler 55 gallon 3ft 10 in 8 ft 8 in 13 ft 7 in NA NA 1 2m 2 6m 41m 30 gallon 3ft 10 in 8 ft 8 in 13 ft 7 in NA NA 1 2m 2 6m 41m Note measured from ground to bottom of barrel Load Platform forks down 4 ft 101 2 in 9 ft 9 in 14 ft 71 2 in 19 ft 6 in 24 ft 4 in 1 5m 3m 4 5m 6m 7 4m forks up 6 ft 7 in 11 ft 51 2 in 16 ft 4 in 21 ft 21 2 in 26 ft 1 2 in 2m 3 5m 5m 6 5 m 79m Note can be used with standard forks and adjustable forks only Pipe Cradle Option handles round objects up to 30 in 76 cm in diameter Note can be used with standard forks and adjustable forks only see above for working heights Non marking Fork Option Note can be used with standard forks and adjustable forks only see above for working heights Fork Extension Option adds 61 4 to 25 inches 15 to 64 cm of length to forks Note can be used with standard forks and adjustable forks only see above for working heights Airborne Noise Emissions 85 dB 85 dB 85 dB 85 dB 85 dB by Machinery Maximum sound level at normal operating workstations A weighted Genie Superlift Advantage Part No 80170 October 2004 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey M Maintena
43. er the carriage 2 Remove the cable retaining fastener from the winch drum Remove the cable from the winch drum 10 Remove the winch housing from the machine 4 Remove the drum bolt and the drum bolt spacer Remove the drum drum gear cover and housing spacer from the winch 5 Remove the two lock nuts from the pinion shaft by holding the opposite end of the shaft at the flattened portion of the threads Component damage hazard Be CAUTION careful not to damage the threads while holding the pinion shaft 6 Remove the retaining ring from the pinion shaft 5 10 Genie Superlift Advantage Part No 80170 October 2004 Section 5 Repair Procedures REV A How to Assemble a One speed Winch Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable Refer to Figure 8 E One speed Winch for an exploded view of the winch 1 Place one side of the winch housing over the jaws of a vise Open the vise until the jaws are wider than the outside diameter of the bushing 2 Insert a soft metal drift through the opposite bushing hole Tap the drift with a rubber mallet to push the bushing into place 3 Repeat steps 1 and 2 to insert the other bushing Use a piece of flatbar or wood in between the drift and the bushing to prevent any damage to the bushing 4 Add two drops of 30W oil to both pivot points on each ratchet pawl CAUTION Component damage hazard Do not allo
44. g t a FF Genie gt Parts amp Service Manual Refer to inside cover for serial number information December 2005 Superlift Advantage after serial number SLA04 25258 Introduction December 2004 Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us www genieindustries com e mail techsup genieind com Serial Number Information Genie Industries offers the following Service Manuals for these models Title Part No Genie Superlift Advantage Parts and Service Manual First Edition before July 2001 32283 Genie Superlift Advantage Parts and Service Manual Second Edition atter J ne 2001 ur ee 80170 Copyright 1994 by Genie Industries 80170 Rev B October 2004 Second Edition Second Printing Genie is a registered trademark of Genie Industries in the USA and many other countries SLA is a trademark of Genie Industries 4 Printed on recycled paper Printed in U S A ii Genie Superlift Advantage Part No 80170 December 2005 How T
45. gth Width Depth Net Weight Standard Forks 271 2 in 231 2 in 2 2in 38 Ibs 70 cm 60 cm 6 4 cm 17 2 kg Adjustable Forks 271 2 in 111 2 in to 30 in 2 2in 52 5 Ibs 70 cm 29 cm to 76 cm 6 4 cm 23 8 kg Flat Forks 32 in 16 in to 31 in 11 2 in 73 Ibs 81 cm 41 cm to 79 cm 3 8 cm 33 1 kg Boom 18 in to 42 in 11 2 in 61 2 in 34 5 Ibs 46 cm to 1 1m 4 cm 16 5 cm 15 6 kg Vertical Barrel Stacker 21 in 29 in NA 50 5 Ibs 53 cm 74 cm 22 9 kg Rotating Barrel Handler 29 in 31 in NA 90 lbs 74 cm 79 cm 40 8 kg Pipe Cradle 271 2 in 241 2 in 6 in 10 Ibs 70 cm 63 cm 15 2 cm 4 5 kg Load Platform 271 2 in 231 2 in 21 2 in 26 5 lbs 70 cm 60 cm 6 4 cm 12 kg Fork extensions each 30 in 2in 3 in 4 5 Ibs 76 cm 5 cm 7 6 cm 2 kg Part No 80170 Genie Superlift Advantage 2 1 Section 2 Specifications October 2004 ZZA SPECIFICATIONS REV A Dimensions SLA 5 SLA 10 SLA 15 SLA 20 SLA 25 Standard Forks Forks Down 4 ft 101 2 in 9 ft 9 in 14 ft 71 2 in 19 ft 6 in 24 ft 4 in 1 5m 3m 45m 5 9m 7 4m Forks Up 6 ft 7 in 11 ft 51 2 in 16 ft 4 in 21 ft 21 2 in 26 ft 1 2 in 2m 3 5m 5m 6 5 m 79m Adjustable Forks Forks Down 4 ft 101 2 in oft9in 14 ft 71 2 in 19 ft 6 in 24 ft 4 in 1 5m 3m 4 5m 6m 74m Forks Up 6 ft 7 in 11 ft 51 2 in 16 ft 4 in 21 ft 21 2 in 26 ft 1 2 in 2m 3 5m 5m 6 5 m 79m Flat Forks 4 ft 101 2 in 9 ft 9 in 14 ft 71 2 in NA NA 1 5m 3m 45m Boom 5 ft 101 2 in 10 ft 9 in 15 ft 71 2 in 20 ft 6 in 24 ft 4 in 1 8m 3 3m 4 8m 6 2m 7 4m Note m
46. ii How To Read Your Serial Number iii Recommended Parts Stocking List xi How To Order Parts fiunstighans domain ZLA dw dd oddsen gene OC xii Service Parts Fax Order Form xiii Section 1 Safety Rules General Safety Rules sis v Section 2 Rev Specifications A SE EE sean picasa sey EAE EER 2 1 A SEA 1O unne 2 1 A SE ERE EE EE LL 2 1 A EEE EE EE ini nain 2 1 A SLA 25 een ee ernannt rh emsacenia ties 2 1 Section 3 Rev Scheduled Maintenance Procedures ad oe 1102 10 EE Ria RAA AE a RPW w 3 1 Pre delivery Preparation Report ss 3 3 Maintenance Inspection Report e eeeeeea aaa ee aaa aaa aaa anawa aaa 3 5 B Checklist A Procedures A 1 Perform Pre operation Inspection eeeeeaaaa aaa aaa aaa aaa aninaaa 3 6 A 2 Perform Function Tests e eeeee sau eea aaa aaa aaa Eaa anadi 3 6 B Checklist B Procedures BI I spectall Welds 4 sz id OG WO R aS a OE 3 7 B 2 Clean the Columns ss 3 7 B 3 Check the Winch Operation 3 8 B 4 Inspect and Lubricate the Winch eeoeeeeee aaa aaa aaa aaa anna 3 8 B 5 Inspect the Carriage Hold down Bar 3 10 Part No 80170 Genie Superlift Advantage vil April 2005 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued B Checklist C Procedures C 1 Lubricate the Casters and Wheels 3 11 C 2 Inspect the Mast Assembly for Wear ruunvrnnrnnrrnnenvrrnnnnnrnnrrnrrnnnrnnnn 3 11 C 3 Replace the Winch Fricti
47. insert even amounts of cable into each end of the tool Tighten the set screws i RU Place a smooth layer of strapping tape over the joint section of the two cables and the tool Ts If the cable gets caught as you are pulling it through the columns and pulleys avoid pulling too hard as you may break the connection between the two cables Try pulling the cable back and forth until the cable pulls freely Part No 80170 Genie Superlift Advantage 5 7 Section 5 Repair Procedures October 2004 MAST ASSEMBLY 7 Pull on the old cable while feeding the new cable through the machine 8 When the taped area appears at the winch loosen the set screws and remove the old cable 9 Attach the new cable to both the mast anchor and the winch drum 10 Wind the new cable evenly onto the winch drum Be sure there are at least four wraps of cable on the winch drum 11 Fully raise and lower the carriage without a load to check for proper operation The carriage should raise and lower smoothly 12 Fully raise and lower the carriage again with a load and check for proper operation The carriage should raise and lower smoothly Do not use as a load carryin ACAUTION Zo cable splice This tool is intended for cable replacement only REV A 2 3 Lifting Pulley How to Replace a Lifting Pulley Mast Installed 1 Fully lower the carriage 2 Unwind approximately 1 to 2 feet 30 to 60 cm of cab
48. lace a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Part No 80170 Genie Superlift Advantage 3 5 Section 3 Scheduled Maintenance Procedures October 2004 Checklist A Procedures A 1 Perform Pre operation Inspection Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine REV B A 2 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie Superlift Advantage Part No 80170 October 2004 Section 3 Scheduled Maintenance Procedures
49. le from the winch drum 3 Tip the machine backwards and rest the top of the number one mast on a suitable structure capable of supporting it Secure the top of the mast to the structure 4 Attatch an overhead crane to the base Lift the machine to a horizontal position and slide a second structure under the mast next to the base 5 Ifreplacing an upper pulley slide the column that is above the pulley to be replaced forward If replacing a lower pulley slide the column with the pulley to be replaced forward Push the column forward approximately 6 inches 15 cm to expose the lower column stop Remove the column stop mounting fasteners 7 Slide the column backwards until the pulley that is to be replaced is exposed 8 Remove the two mounting fasteners from the pulley mounting block Remove the pulley assembly 9 Remove the retaining fastener that attaches the pulley to the mounting block Note the quantity and location of the shims and spacers before disassembling 10 Remove the old pulley 11 Install the cable onto the new pulley 5 8 Genie Superlift Advantage Part No 80170 October 2004 Section 5 Repair Procedures REV A MAST ASSEMBLY 12 Apply Loctite removeable thread sealant to the pulley mounting fastener and install the fastener through the pulley and pulley guard into the pulley mounting block A a pulley b pulley guard c pulley mounting block AWARNING Crushing hazard Failure to
50. nce procedures shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance procedures shall be completed daily quarterly and annually as specified on the maintenance inspection report AWARNING Failure to properly complete each inspection when required could result in death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating machine M Keep records on all inspections for three years M Be sure the capacities of sawhorses or other supports are sufficient to withstand machine weight See Specifications section for the machine weight M Be sure overhead cranes or other lifting devices are of ample capacity to handle machine weight See Specifications section for machine weight M Unless otherwise specified perform each procedure with the machine in the following configuration Machine positioned on a firm level surface Carriage fully lowered Casters locked Load handling attachment installed About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol
51. nd safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Part No 80170 Genie Superlift Advantage October 2004 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presense of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance i
52. nformation Be sure to wear protective eye wear and Ft other protective clothing if the situation warrants it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Be aware of potential crushing hazards Ej Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas N are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that your workshop or work area STU B is properly ventilated and well lit other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure that fasteners intended for one A time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time a Be sure to properly dispose of old oil or 4 other fluids Use an approved container Please be environmentally safe vi Genie Superlift Advantage Part No 80170 December 2005 Table of Contents Introduction Important Informations aaa Rennen
53. nvrnnnnnrnnnrrrrrnnnnnvnnrnnrrnnnennrenennnnnnnnn 7 8 Section 8 Rev Mast and Winch Components Figure 8 A B Mast Components View ee a 8 2 Figure 8 B B Mast Components View 2 8 4 Figure 8 C C Mast Components View 3 sirsiran ra ia aias 8 6 Figure 8 D C Columns Pulleys and Cables sessies anie 8 10 Figure 8 E C Winch Components One speed rrrnannnnvvnrnnvnnnnvnrrnnnnnnvnnrnrrnnnannrenernnrnenennn 8 14 Figure 8 F C Winch Components Two speed rrrrrnnnnnvrnnnnvrenrrrrrrnnnnnnerrrrannennnensrnnrnnsennn 8 16 Section 9 Rev Accessories Figure 9 A B FOKO die o i R ne a aee 9 2 Figure 9 B B Pipe Cradle Load Platform and Boom Arm ee eaa aaa aaa eaaaaacwna 9 4 Figure 9 C B Rear Wheels wozi e ner etienne n es 9 6 Part No 80170 Genie Superlift Advantage ix October 2004 ZLA Notes X Genie Superlift Advantage Part No 80170 October 2004 Recommended Parts Description Genie Gray Paint 12 Ounce 355 ml Aerosol 1268 Genie Blue Paint 12 Ounce 355 ml Aerosol 1484 Genie Blue Paint 1 Gallon 3 78 liters 32150 Genie Gray Paint 1 Gallon 3 78 liters 32151 Pinion Plate One speed Winch 1 11 7591 Pinion Plate Two speed Winch 40122 Ratchet Gear One speed Winch 6777 Ratchet Gear Two speed Winch 4012
54. o Read Your Serial Number Genie Model GS 1930 Serial number GS3005A 12345 Model year 2005 Manufacture date 04 12 05 Electrical schematic number ES0141 Machine unladen weight 2 714 Ib 1 231 kg Rated work load including occupants 500 Ib 227 kg Maximum allowable inclination of the chassis N A GS30 05 A 12345 Gradeability N A Model Maximum allowable side force 100 Ib 445 kg Sequence Maximum number of platform occupants 2 number Model year Country of manufacture USA This machine complies with Facility code used only for model manufactured ANSI A92 6 1999 in multiple facilities B354 2 01 Genie Industries 18340 NE 76th Street Redmond WA 98052 USA PN 77055 Part No 80170 Genie Superlift Advantage iii December 2005 LL TI This page intentionally left blank iv Genie Superlift Advantage Part No 80170 October 2004 Safety Rules Warning Failure to obey the instructions and safety rules in this manual and the Genie Superlift Advantage Operator s Manual could result in death or serious injury Many of the hazards identified in the operating instruction manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions a
55. oints on each ratchet pawl CAUTION Component damage hazard Do not allow grease or oil onto the friction disks or the ratchet gear 5 Install the winch housing on the mast Be sure the winch drum is toward the top 6 Insert the longer threaded end of the pinion shaft approximately halfway through the right side bushing REVA 7 Apply a small amount of multi purpose grease to the large threaded section of the pinion shaft under the gear nut Slide the pinion shaft gears onto the pinion shaft Install the pinion gear onto the pinion shaft with the gears toward the right side of the winch housing Screw onto large threads hand tight 8 Install in order a friction disk a ratchet gear a friction disk a pinion plate and a pinion spacer onto the pinion shaft CAUTION Component damage hazard Do not allow grease or oil onto the brake disk ratchet gear or the teflon spacer The teeth on the ratchet gear must curve toward the left side of the winch housing 9 Install the pinion shaft retaining ring onto the pinion shaft Use your fingers to push the ratchet pawls outwards while pushing the pinion shaft through the left bushing Be sure the ratchet pawls are in firm contact with the ratchet gear and that all parts move freely 10 Install the lock nut on the left side of the pinion shaft 11 Install the input shaft approximately half way through the left side of the winch housing 12 Slide the left side bushing sp
56. on 7 Base Components mE sssss REV C FIGURE 7 C Item Part No Description Qty item Part No Description Qty 37481 Stabilizer Set Assembly 24 6732 Screw HHG includes items 2 5 16 18 1 2 13 x 3 25 inches GR 5 and 22 30 25 32519 Stabilizer Latch Spring 2 EE Brae Late 7 See Ga 2 g 198 NYDSENUL TE 27 11337 Roll Pin 0 25 x 1 25 inches 2 j ener ist Masher veel 28 32577 Stabilizer Latch Plate 6 4 a AM che CRE 29 32578P Stabilizer Tube 2 5 35212 S Stabilizer Mount Bracket za 30 32576 Stabilizer Pivot Tube 2 6 Ref Standard Base Assembly with Decals refer to Figure 7 A 7 32509 Leg Pivot Tube 2 8 6175 Screw HHC 3 8 16 x 1 inch GR5 9 32879 Leg SLA 5 and SLA 10 2 32880 Leg SLA 15 32881 Leg SLA 20 and SLA 25 10 57736 Front Swivel Caster 4X2 INGES EE 2 11 32524 Leg Axle Tube 222111121 12 2 12 57783 Wheel 3 5 x 1 25 inches 2 13 32499 E Clip 0 875 inch einer 4 14 33373 Shim Washer 0 938 x 1 5 x 0 09 inch 4 15 10598 Screw HHC 1 2 13 x 3 inches GR5 16 6086 Low Profile Nylock Nut 1 2 13 17 100309 Pin Assembly with Lanyard 2 18 57746 Side Swivel Caster 3 5 x 1 25 inches 1 2 19 6034 Hex Jam Nut 1 2 13 20 6033 Lock Washer 1 2 inch 21 6095 Flat W
57. on Discs rrrrnnnnnrrnnnnnnvnnnrrrrrnnennrnnrnnrnnnernnnn 3 13 C 4 Inspect the Safety Brake System if equipped 111 1 3 13 C 5 Inspect the Painted Surfaces rrnnrnvrnnnnnnrnnrnnrrnnnnnrnnnnnnrnnrrrrrrennnnnnnnn 3 15 Section 4 Rev Troubleshooting Flow Charts I trodUcUOM ersehen 4 1 B Chart 1 Mast Will Not Sequence Properly ss ee eaee aaa aaa aaa aa aaaaaeci 4 2 Chart 2 Carriage Will Not Raise But Winch Will Operate 4 3 B Chart 3 Winch Will Not Operate eeeeaa eee aaa aaa aaa aaa aaa nenn 4 4 Section 5 Rev Repair Procedures Introduelion eu ee OE A A EA ET 5 1 B 1 l BAS an ie to Oaza a 5 2 21 Mast Assembly anti alien etant minier 5 3 2 2 Lifting Gable sc ai aa 22 eee a eee 5 7 2 3 Lt Pully ee een 5 8 3 1 One speed Winch rnnrnnrnnnnnnrrnnnnnnvnnnnnrnnnnrnvrenannnvnnnnnrnnnnnnnrenennnnnnnenn 5 10 8 2 TWo speed Winchester garnieren 5 13 viii Genie Superlift Advantage Part No 80170 December 2005 EEE TABLE OF CONTENTS Section 6 Rev Decals and Paint Figure 6 A B DEec ls nne ee nn 6 2 Figure 6 B B Decals with Words se 22 nee ee 6 4 Figure 6 C B Decals with Symbols nn 6 6 Section 7 Rev Base Components Figure 7 A B Base Components Standard naar 7 2 Figure 7 B B Base Components Straddle SLA 5 SLA 10 and SLA 15 7 6 Figure 7 C C Base Components All Models rrnnnnrrrnnnn
58. ong machine life An unsafe working condition exists if there is damage to painted surfaces that is not corrected 1 Visually inspect all painted surfaces for the following conditions Blistering Rust Peeling Fading Corrosion Replace any component that is damaged Part No 80170 Genie Superlift Advantage 3 15 Section 3 Scheduled Maintenance Procedures October 2004 MM UO uuu This page intentionally left blank 3 16 Genie Superlift Advantage Part No 80170 October 2004 Section 4 Troubleshooting Flow Charts Troubleshooting Flow Charts Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine M Be sure the capacities of sawhorses or other supports are sufficient to withstand machine weight See Specifications section for specific weight M Be sure overhead cranes or other lifting devices are of ample capacity to handle machine weight See Specification section for specific weight Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie Superlift Advantage Operator s Manual M Be sure that all necessary tools and test equipment are available and ready for use M Read each app
59. ore serial number SLA03 20409 1 80986 Cable Anchor after serial number SLA03 20408 5 6052 Shim Washer 0 5 x 0 875 x 0 063 inch 7 6 6086 Low Profile Nylock Nut 1 2 13 7 Ref Cable Assembly refer to Figure 8 D 8 32475 Roller Bolt 1 2 13 x 1 84 inches 8 9 13066 Hardened Flat Washer 1 2 inch 10 32473 Roller 1 75 x 0 72 inch 8 11 32474 Roller Guard 5 12 Ref Carriage refer to Figure 8 D 13 57016 Doubler Plate 1 14 Ref Number 1 Column refer to Figure 8 D Part No 80170 Genie Superlift Advantage 8 5 Section 8 Mast and Winch Components April 2005 Figure 8 C Mast Components View 3 0000000 OG REV C x x eb IR Ur Safety Brake Assy T Optional gt nue e N GC OOO WM 8 6 Genie Superlift Advantage Part No 80170 April 2005 REV C litem Part No 1 6198 2 6095 109560 3 Ref 4 32474 32474 32474 32474 32474 5 32473 32473 32473 32473 32473 6 32475 32475 a 32475 32475 32475 Description Nylock Nut 1 2 13 SLA 5 SLA 10 SLA 15 SLA 20 and
60. p handling attachment the adjacent column 9 Grasp the bottom side of the next column and lift it approximately 12 inches 30 cm then release the column c Result The carriage should stop within 5 to 8 inches 12 to 20 cm and the safety brake A R should engage Crushing hazard Do not stand 4 Raise the carriage approximately 12 ACAUTION directly a the columns or load inches 30 5 cm to disengage the safety handling attachment brake f 5 Operate the winch until the front column is half way up the adjacent column 6 Grasp the bottom of the front column and lift it approximately 5 inches 12 cm then release the column O Result The carriage should stop within 5 to 8 inches 12 to 20 cm and the safety brake should engage 10 Repeat steps 7 through 9 to test all remaining ACAUTION Crushing hazard Do not stand columns directly under the columns or load When disengaging the safet handling attachment e 4 brake it may be necessary to hold down the column behind the column to be disengaged The number one column column attached to the base does not have a safety brake and will not need to be tested 3 14 Genie Superlift Advantage Part No 80170 October 2004 Section 3 Scheduled Maintenance Procedures E sms REV B CHECKLIST C PROCEDURES C 5 Inspect the Painted Surfaces Inspecting the painted surfaces of your machine is essential to safe operation and l
61. ring and ball housing spacer input shaft gears and right side bushing onto the input shaft Genie Superlift Advantage Part No 80170 October 2004 Section 5 Repair Procedures REV A 13 Install the ball and spring into the spring and ball housing Install the mounting fasteners 14 Lubricate the outside of the frame spacer with multi purpose grease and insert it into the drum 15 Install the cable drum Be sure the drum gears mesh with the ratchet gears 16 Install the drum bolt keeper Push the drum bolt through the winch housing drum cover and drum Be sure the head of the drum bolt is on the drum gear side of the winch 17 Install the drum bolt jam nut and torque to 20 to 25 ft lbs 27 to 34 Nm Component damage hazard CAUTION Overtightening the drum bolt jam nut may cause damage to the frame spacer and prevent the drum from spinning freely 18 Lubricate the teeth of the drum gear and the pinion nut with multi purpose grease CAUTION Component damage hazard Do not allow grease or oil onto the friction disks or the ratchet gear 19 Install the input shaft cover 20 Rotate the winch drum so that the oblong slot is visible and horizontal 21 Install the cable keeper clip on the outside of the winch drum with one carriage bolt coming through from the inside Install the lock washer and nut finger tight Do not tighten the nut WINCHES 22 Route the end of the cable between the winch drum and
62. ropriate flow chart thoroughly Attempting shortcuts may produce hazardous conditions M Be aware of the following hazards and follow generally accepted safe workshop practices ADANGER Crushing hazard When testing or replacing the primary component always support the structure and secure it from movement Perform all troubleshooting on a firm level surface Two people will be required to safely perform some troubleshooting procedures About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools are required General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Perform repair Return to service problem solved Part No 80170 Genie Superlift Advantage 4 1 Section 4 Troubleshooting Flow Charts October 2004 Chart 1 Mast Will Not Sequence Properly Be sure safety brake if equipped is not engaged by fully raising and lowering all columns Improper sequencing of the mast columns may occur when the machine is at or near maximum capacity If improper sequencing occurs the columns may shift to their correct position during operation or when the load is removed The forks will not change position if the columns shift position The carriage should always raise first
63. rther than necessary 18 Install all the components removed during disassembly Be sure that all fasteners have Loctite removeable thread sealant applied to the threads and that all fasteners have been securely tightened 19 Attach the cable to the winch and be sure the cable is routed correctly 20 Raise the machine to full height to release the safety brakes if equipped and verify proper operation Genie Superlift Advantage Part No 80170 October 2004 Section 5 Repair Procedures REV A 2 2 Lifting Cable How to Replace the Lifting Cable ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable All Genie replacement cables come with one pre swaged end that terminates at the top of the last column and one taped end that terminates at the winch For additional information refer to instructional video Genie Superlift Cabling Procedure This video is available from Genie Industries Genie part number 52701 1 Fully lower the carriage 2 Remove the retaining fasteners from the eyelet end of the cable at the mast anchor plate and cut the eyelet off below the copper sleeve 3 Remove the old cable from the winch drum MAST ASSEMBLY Unwind the outer strands and trim them back 1 2 inch 13 mm leaving the core longer Repeat this process on the open end of the new cable Using the cable threading tool supplied with your cable
64. s than specification Friction disk specification Thickness minimum 1 16 inch 1 5 mm 4 Measure both shaft bushings for wear Replace the bushings if the wall thickness measurements are less than specification Pinion shaft bushing specification Wall thickness minimum 1 8 inch 3 1 mm 5 Lubricate the surface of the frame drum spacer with a thin layer of lithium grease Tighten the drum bolt to 20 ft lbs 27 Nm Do not overiighten Part No 80170 Genie Superlift Advantage 3 9 Section 3 Scheduled Maintenance Procedures October 2004 EEE CHECKLIST B PROCEDURES REV B B 5 Inspect the Carriage Hold down Bar Detection of damage to the column hold down system is essential for safe machine operation An unsafe working condition exists if the system is damaged and does not operate properly 1 Using proper lifting techniques lay the machine back against a sawhorse or other suitable support 2 Visually inspect the carriage hold down bar for damage 3 Check the carriage hold down bar for smooth operation 3 10 Genie Superlift Advantage Part No 80170 October 2004 Section 3 Scheduled Maintenance Procedures eve Checklist C Procedures C 1 C 2 Lubricate the Inspect the Casters and Wheels Regular application of lubrication to the Caster or Wheel is essential to good machine performance and service life Extremely dirty conditions may require that the casters and wheels be inspected and li
65. side Part No 80170 Genie Superlift Advantage 5 3 Section 5 Repair Procedures October 2004 MAST ASSEMBLY 5 Remove the cable from the mast by pulling on the cable anchor end of the cable Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable 6 Slide the carriage up approximately 12 inches 30 cm to expose the column stop mounting fastener attached to the bottom end of the top column Remove the fasteners and the column stop 7 Models with safety brake Insert a hex key wrench through the access holes in the carriage to release the safety brake Position the hex key above the safety brake rollers Slide the carriage away from the base while pulling back on the wrench a mi gt 4 o i o pe 20 L a Brake roller b Brake release tool c Column or carriage REVA 8 Models with safety brake Remove the carriage by sliding it out the bottom of the mast toward the base while holding the safety brake rollers in the released position with the hex key wrench Models without safety brake Remove the carriage by sliding it out the bottom of the mast toward the base 9 Slide the column up approximately 12 inches 30 cm to expose the column stop mounting fasteners attached to the bottom end of the top column Remove the fasteners and the column stops 10 Models wi
66. side of the winch housing Note the location and position of the components on the pinion shaft 11 Slide the pinion shaft to the right and remove the pinion spacer pinion plate ratchet gear and friction disks Turn the pinion gear counterclockwise and slide it off the left side of the shaft 12 Remove both pinion bushings Use a soft metal drift equal to the outside diameter of the bushing and tap with a rubber mallet Component damage hazard CAUTION Place a block between the walls of the winch housing to prevent the housing from bending while removing the bushings Part No 80170 Genie Superlift Advantage Section 5 Repair Procedures October 2004 WINCHES How to Assemble a Two speed Winch Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling cable Refer to Figure 8 F Two speed Winch for exploded view of the winch 1 Place one side of the winch housing over the jaws of avise Open the vise until the jaws are wider than the outside diameter of the bushing 2 Insert a soft metal drift through the opposite bushing hole Line up the tab on the bushing to the hole in the winch housing Tap the drift with arubber mallet to push the bushing into place 3 Repeat steps 1 and 2 to insert the other bushing Use a piece of flatbar or wood between the drift and the bushing to prevent any damage to the bushing 4 Add two drops of 30W oil to both pivot p
67. ssembly 8 Attach the swaged end of the cable to the cable anchor on the top of the front column Part No 80170 Genie Superlift Advantage 5 5 Section 5 Repair Procedures October 2004 MAST ASSEMBLY 9 Feed the other end of the cable through the box section web of the carriage into the pulley then push the cable through the pulley until it comes out the back side of the carriage ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable Refer to Figure 8 D in the Parts Section to identify the cable routing 10 Insert the carriage into the bottom end of the top column Hold the carriage in place and pull the cable up to the top of the column leaving enough slack to feed the cable through the next pulley 11 Push the cable through the exposed portion of the pulley at the top of the column until the cable reaches the pulley at the bottom of the column 12 Remove the lower pulley assembly from the upper column 13 Route the cable into and around the lower pulley REV A 14 Apply Loctite removeable thread sealant to the pulley mounting fastener and install the lower pulley into the column 15 Push the cable between the two mast sections until it comes out the top of the column 16 Repeat steps 11 through 15 with all remaining columns 17 Slide all the columns forward until you can install the column stops Do not slide the columns forward any fa
68. stiff wire bent in an L shape with one end 1 inch 25mm long and the other end 16 inches 41 cm long The installation of a handle on the long end will make it easier to use This tool is available from Genie Industries Genie part number 33875 Insert the tool from the bottom of the column into the safety brake access slot in the inner side wall of the column Reach through the far upper end of the slot and position the short end of the tool above the safety brake rollers Slide the carriage away from the base while pulling back on the tool MAST ASSEMBLY How to Assemble the Mast 1 Inspect all mast parts for wear and damage Replace as necessary 2 Clean all columns and rollers 3 Clean all safety brake assemblies if equipped 4 Position the number one column so that it is open side up and level If it is not attached to the base secure the column to the supports 5 Install all column assembly components removed during disassembly except the column down stops Apply a small amount of multi purpose grease between the roller bolt head and the inside of the roller wheel 6 Slide the number two column into the number one from the bottom Stop inserting the column when the top of the up stop or the safety brake assembly is even with the bottom edge of the number one column 7 Repeat steps 4 through 6 with all remaining columns Do not install the carriage The cable is installed after all columns are together as an a
69. tandard Base Assembly with Decals SLA 10 before serial number SL04 25259 Standard Base Assembly with Decals SLA 10 after serial number SL04 25258 USA Canadian and Australian models after serial number SLA04 25258 Standard Base Assembly with Decals SLA 10 after serial number SL04 25258 Asia S America and European models after serial number SLA04 25258 Standard Base Assembly with Decals SLA 15 before serial number SL04 25259 Standard Base Assembly with Decals SLA 15 after serial number SL04 25258 USA Canadian and Australian models after serial number SLA04 25258 Standard Base Assembly with Decals SLA 15 after serial number SL04 25258 Asia S America and European models after serial number SLA04 25258 Standard Base Assembly with Decals SLA 20 before serial number SL04 25259 ltem Part No 2 0 11 12 107174 107184 80175 S 107175 107185 21443 33658 6175 4828 57740 6019 33670 8516 6097 12016 Section 7 Base Components FIGURE 7 A Description Qty Standard Base Assembly with Decals SLA 20 after serial number SL04 25258 USA Canadian and Australian models after serial number SLA04 25258 Standard Base Assembly with Decals SLA 20 after serial number SL04 25258 Asia S America and European models after serial number SLA04 25258 Standard Base Assembly with Decals SLA 25 before serial number SL04 25259
70. ted SLA 5 SLA 10 SLA 15 SLA 20 and SLA 25 models Up Stop for models without safety brake SLA 5 1 Up Stop for models without safety brake SLA 10 2 Up Stop for models without safety brake SLA 15 3 Up Stop for models without safety brake SLA 20 4 Up Stop for models without safety brake SLA 25 5 Safety Brake Assembly if equipped SLA 15 includes items 8 and 9 2 Safety Brake Assembly if equipped SLA 20 includes items 8 and 9 3 Safety Brake Assembly if equipped SLA 25 includes items 8 and 9 3 Down Stop na 1 Screw HHC 3 8 16 x 1 25 inches GR 5 Shim Washer 0 375 x 0 625 x 0 063 inch 1 Nylock Nut 3 8 16 Shim Washer 0 5 x 0 875 x 0 063 inch SLA 5 SLA 10 SLA 15 SLA 20 and SLA 25 models This list continues on the next page Part No 80170 Genie Superlift Advantage Section 8 Mast and Winch Components April 2005 FIGURE 8 C REV C Ur Safety Brake Assy T Optional gt e N GC OOO WM 8 8 Genie Superlift Advantage Part No 80170 April 2005 Section 8
71. th safety brake Insert a hex key wrench through the access holes in the column up to release the safety brake Position the hex key above the safety brake rollers Slide the carriage away from the base while pulling back on the wrench k Models with safety brake Remove the column by sliding it out the bottom of the mast toward the base while holding the safety brake rollers in the released position with the hex key wrench Models without safety brake Remove the column by sliding it out the bottom of the mast toward the base 12 Repeat steps 10 through 12 for each remaining column 5 4 Genie Superlift Advantage Part No 80170 October 2004 Section 5 Repair Procedures REV A How to Release the Safety Brake When Servicing the Mast The safety brake system can engage when the machine is tilted horizontally if the hold down bar is not used When the brake is engaged the columns can extend but not retract If the safety brake system engages while you are servicing the mast use one of the following methods described below to release the brake Method A This method allows you to release each column in sequence starting at the carriage and removing columns one at a time See 2 1 How to Disassemble the Mast Assembly Method B This method allows you to release any column in the assembly regardless of it s position but requires a custom tool The tool is a piece of 1 8 to 5 16 inch 3 2 to 8 mm diameter
72. the number one column Proceed around the drum and up through the horizontal slot in the winch drum The cable is then fed under the lefthand side of the cable clip pulled forward looped and then fed under the right hand side of the cable keeper clip The raw end of the cable is then fed into the righthand side of the horizontal slot in the winch drum AWARNING Crushing hazard Failure to proprely route the cable may result in a winch brake failure a Number one column b Cable c Cable keeper clip d Winch drum 23 Tighten the cable keeper fastener 24 While holding the cable tight on the drum rotate the drum with a handle and spool the cable onto the drum evenly CAUTION Component damage hazard Be sure the cable winds onto the winch drum evenly Part No 80170 Genie Superlift Advantage Section 5 Repair Procedures October 2004 m ZE E ZZ A SOO Ny This page intentionally left blank 5 16 Genie Superlift Advantage Part No 80170 October 2004 Section 6 Decals Section Six Decals Part No 80170 Genie Superlift Advantage 6 1 October 2004 Section 6 Decals F REV B 6 A igure 7 One Speed Winch Two Speed Winch
73. uropean models after serial number SLA04 25258 includes items 12 and 14 Hold down Assembly with Decals SLA 20 and SLA 25 before serial number SLA04 25289 USA Canadian and Australian models after serial number SLA04 25258 includes items 12 and 14 Hold down Assembly with Decals SLA 20 and SLA 25 Asia S America and European models after serial number SLA04 25258 includes items 12 and 14 Glide Button 1 Toggle Pin 0 5 x 7 75 inches 1 Carriage refer to Figure 8 D Section 7 Base Components FIGURE 7 A Part No 80170 Genie Superlift Advantage Section 7 Base Components October 2004 Figure 7 B Base Components Straddle SLA 5 SLA 10 and SLA 15 o REV B 2 7 6 Genie Superlift Advantage Part No 80170 October 2004 REV B litem Part No 1 2 3 11 12 13 14 16 17 18 19 Ref 33148 33251 32531 21443 33658 6019 4828 80176 S 80177 S 80178 S 57740 35408 46683 40255 33670 8516 6097 28487 32532 58750 Description Qty item Part No Columns refer to Figure 8 D 19 107153 Straddle Base Knob 2 Straddle Base Spacer 3 INCRES svie 2 Arm Straddle Right Side 1 Shim Washer 20 12019 0 45 x 0 75 x 0 063 inch 3 21 11890 Hold down Spring
74. vantage 9 7 Section 9 Accessories October 2004 Notes 9 8 Genie Superlift Advantage Part No 80170 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 617 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 3409612 Fax 46 31 3409613 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie G rmany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 10 220 7911 Fax 31 10 220 6642 Parts and Service Manual Superlift Advantage after serial number SLA04 25258 Part No 80170
75. w grease or oil onto the brake disks or the ratchet gear 5 Install the winch housing onto the mast Be sure the winch drum is toward the top 6 Insert the longer threaded end of the pinion shaft approximately halfway through the left bushing WINCHES 7 Apply a small amount of multi purpose grease to the large threaded section of the pinion shaft under the gear nut Screw the pinion gear onto the pinion shaft with the gears toward the left side of the winch housing Install in order a brake disk a ratchet gear a brake disk a pinion plate and a pinion spacer onto the pinion shaft CAUTION Component damage hazard Do not allow grease or oil onto the brake disks or the ratchet gear The teeth on the ratchet gear must curve away from the right side of the winch housing Push the pinion shaft to the right through the right pinion bushing and install the pinion shaft retaining ring Use your fingers to push the ratchet pawls outward while pushing the pinion shaft through the right bushing Be sure the ratchet pawls are in firm contact with the ratchet gear and that all parts move freely 10 Install the two jam nuts to the right side of the pinion shaft one at a time and tighten 11 Position both handles on the pinion shaft in opposite directions Install and tighten the lock nuts Part No 80170 Genie Superlift Advantage 5 11 Section 5 Repair Procedures October 2004 WINCHES 12 Lubricate the
76. wer the carriage Remove the load handling attachment from the machine Models with stabilizers 4 Remove the mounting fasteners from the stabilizer mounting bracket on the back of the mast Remove the mounting fastener from each stabilizer at the base Remove each stabilizer from the machine All Models 6 Using proper lifting techniques tilt the machine back and rest the loading wheels against a suitable srtucture cable of supporting it ACAUTION Bodily injury hazard Use proper lifting techniques when rolling the mast assembly over REV A 7 Remove the mounting fastener and retaining pin from each leg Remove the legs from the machine 8 Using proper lifting techniques carefuly tilt the machine to the upright position Bodily injury hazard Use proper ACAUTION 209 SAN lifting techniques when tilting the machine to the upright position 9 Attach a lifting strap from an overhead crane to the lifting eye at the top of the number one mast column 10 Position a suitable structure capable of supporting the machine on the carriage side of the mast 11 Carefully lift the machine slightly with the overhead crane While lowering it guide the machine over onto a suitable structure capable of supporting it ACAUTION Crushing hazard The machine may become unbalanced and fall if not properly supported by the overhead crane A Genie Superlift Advantage Part No 80170 October 2

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